Optical micrograph of necked free formed specimen (6.5 kV) at the maximum strain region. Voids (black) due second phase particle (dark gray) fracture and debonding can be seen. Magnification: 100×

Optical micrograph of safe free formed specimen (5.8 kV) at the maximum strain area. Damage is far less severe than that observed in the necked sample. Some evidence of void nucleation due to debonding and particle fraction is present.

Merged 3×3 optical micrograph of “step” region in a conical part. Damage appears to have occurred primarily at the region near the inside surface of the part. Insets A, B, C, and D show that many voids have nucleated due to particle fracture. Magnification: 200×.

Applied pressure vs coil radius

Predicted shape and void volume fraction history for the free-formed part (5% nucleation strain case). A segment of the part has been removed to illustrate the inside of the part. Fringes represent void volume fraction.

Predicted shape and void volume fraction history for the conical part (5% nucleation strain). A segment of the part has been removed to illustrate the inside of the part. Fringes represent void volume fraction.

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